Claims
- 1. A continuous method of making duct liner, comprising the steps of:
forming at least one lane of duct liner insulation having a top and bottom surfaces and a pair of side edges, said duct liner insulation having a facing layer on at least a bottom surface of said duct liner insulation, wherein said bottom surface faces downward after said forming step; flipping said duct liner insulation and facing layer while said duct liner is conveyed, whereby said top surface faces downward and said facing layer faces upward; and applying a water-resistant coating to said upwardly facing facing layer, wherein said duct liner insulation is conveyed as part of a continuous manufacturing process from said forming step to said applying step.
- 2. The method of claim 1, wherein said water-resistant coating comprises an epoxy or latex foam.
- 3. The method of claim 1, further comprising applying said water-resistant coating to said side edges.
- 4. The method of claim 1, wherein said forming step comprises forming at least two lanes of duct liner insulation comprising a first lane of duct liner insulation and a second lane of duct liner insulation, wherein each lane of duct liner insulation comprises a facing layer on a bottom surface thereof, the method further comprising the steps of:
vertically separating said first and second lanes of duct liner insulation; after said vertically separating step, applying said water-resistant coating to said side edges of said lanes of duct liner insulation.
- 5. The method of claim 4, wherein at least one side edge from each of said first and second lanes is substantially horizontally aligned before applying said water-resistant coating to said side edges.
- 6. The method of claim 4, further comprising the steps of:
after said edge applying step, bringing said first and second lanes into a common vertical level; and applying said water-resistant coating to the facing layer of each lane of duct liner insulation.
- 7. The method of claim 6, wherein said forming step comprises an air laid process.
- 8. The method of claim 1, wherein said forming step comprises an air laid process.
- 9. The method of claim 1, wherein said duct liner insulation comprises textile glass fibers, rotary glass fibers, organic fibers, natural fibers or a combination thereof.
- 10. The method of claim 9, wherein said duct liner insulation comprise a non-liquid substantially formaldehyde-free or phenolic binder.
- 11. The method of claim 10, wherein said non-liquid substantially formaldehyde-free binder comprises plastic-containing bonding fibers.
- 12. The method of claim 10, wherein said non-liquid substantially formaldehyde-free binder comprises a thermoplastic or thermosetting powder binder.
- 13. The method of claim 10, wherein said at least one non-liquid substantially formaldehyde-free binder comprises a mixture of plastic-containing bonding fibers and at least one powder binder.
- 14. A continuous method of making duct liner, comprising the steps of:
forming at least two lanes of duct liner insulation each having a top and bottom surfaces and a pair of side edges, each lane having a facing layer on at least one of the top and bottom surfaces; vertically separating said first and second lanes of duct liner insulation; and while said lanes are vertically separated, applying a water-resistant coating to said side edges of said lanes of duct liner insulation.
- 15. The method of claim 14, further comprising the steps of:
after said edge applying step, bringing said first and second lanes into a common vertical level; and applying said water-resistant coating to the facing layer of each lane of duct liner insulation.
- 16. The method of claim 15, wherein said forming step comprises an air laid process.
- 17. The method of claim 14, wherein at least one side edge from each of said first and second lanes is substantially horizontally aligned before applying said applying step.
- 18. The method of claim 14, wherein said lanes of duct liner insulation comprise textile glass fibers, rotary glass fibers, organic fibers, natural fibers or a combination thereof.
- 19. The method of claim 18, wherein lanes of duct liner insulation comprise a non-liquid substantially formaldehyde-free or phenolic binder.
- 21. The method of claim 20, wherein said non-liquid substantially formaldehyde-free binder comprises plastic-containing bonding fibers.
- 22. The method of claim 19, wherein said non-liquid substantially formaldehyde-free binder comprises a thermoplastic or thermosetting powder binder.
- 23. The method of claim 19, wherein said non-liquid substantially formaldehyde-free binder comprises a mixture of plastic-containing bonding fibers and at least one powder binder.
- 24. A continuous system for making duct liner, comprising:
a duct liner forming apparatus, said forming apparatus providing at least one lane of duct liner insulation having a top and bottom surfaces and a pair of side edges, said duct liner insulation having a facing layer on at least a bottom surface of said duct liner insulation, wherein said bottom surface faces downward after said forming apparatus; means for flipping said duct liner insulation and said facing layer while said duct liner is conveyed, whereby said top surface faces downward and said facing layer faces upward; a facing layer coating apparatus positioned to coat said upwardly facing facing layer with a water-resistant coating; and a conveyor, said conveyor conveying said duct liner insulation from said forming apparatus to said coating apparatus.
- 25. The system of claim 24, further comprising an edge coating apparatus positioned to coat said side edges with said water-resistant coating.
- 26. The system of claim 25, wherein said forming apparatus provides at least two lanes of duct liner insulation comprising a first lane of duct liner insulation and a second lane of duct liner insulation, wherein each lane of duct liner insulation comprises a facing layer on a bottom surface thereof, the system further comprising:
means for vertically separating said first and second lanes of duct liner insulation; wherein said edge coating apparatus is positioned after said vertical separation means to coat said side edges of said lanes of duct liner insulation.
- 27. The system of claim 26, wherein at least one side edge from each of said first and second lanes are substantially horizontally aligned before being operated on by said edge coating apparatus.
- 28. The system of claim 26, further comprising:
means for bringing said first and second lanes into a common vertical level positioned before said facing layer coating apparatus.
- 29. The system of claim 26, wherein said vertical separation means comprises a cylindrical barrel around which said duct liner is conveyed.
- 29-38. (canceled).
- 39. The system of claim 24, wherein said duct liner forming apparatus comprises an air laid forming apparatus.
- 40. The system of claim 24, wherein said duct liner comprises textile glass fibers, rotary glass fibers, organic fibers, natural fibers or a combination thereof.
- 41. The system of 40, wherein said duct liner comprise a non-liquid substantially formaldehyde-free or phenolic binder.
- 42. A continuous system for making duct liner:
a duct liner forming apparatus, said forming apparatus forming at least two lanes of duct liner insulation each having a top and bottom surfaces and a pair of side edges, each lane having a facing layer on at least one of the top and bottom surfaces; means for vertically separating said first and second lanes of duct liner insulation; and an edge coating apparatus positioned to apply a water-resistant coating to said side edges of said vertically separated lanes of duct liner insulation.
- 43. The system of claim 42, wherein said vertical separation means comprises a cylindrical barrel around which said duct liner insulation is conveyed.
- 44. The system of claim 42, further comprising:
means for bringing said first and second lanes into a common vertical level positioned after said edge coating apparatus; and a facing layer coating apparatus positioned to coat the facing layer of each lane of ducting liner insulation with a water-resistant coating.
- 45. The system of claim 42, wherein said forming apparatus comprises an air laid forming apparatus.
- 46. The system of claim 42, further comprising means for substantially horizontally aligning at least one side edge from each the first and second lanes positioned before said edge coating apparatus.
- 47. The system of claim 42, wherein said lanes of duct liner insulation comprise textile glass fibers, rotary glass fibers, organic fibers, natural fibers or a combination thereof.
- 48. The system of claim 47, wherein lanes of duct liner insulation comprise a non-liquid substantially formaldehyde-free or phenolic binder.
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. patent application Ser. No. 10/781,994 filed Feb. 19, 2004, entitled “Formaldehyde-Free Duct Liner”, which is a continuation-in-part of the following copending U.S. patent applications Ser. No. 10/689,858, filed on Oct. 22, 2003, U.S. patent application Ser. No. 09/946,476, filed on Sep. 6, 2001, and U.S. patent application Ser. No. 10/766,052, filed on Jan. 28, 2004, which are commonly assigned and hereby incorporated by reference.
[0002] This application is also related to U.S. Pat. No. 6,673,280, issued Jan. 6, 2004, and U.S. patent application Ser. No. 10/766,052, filed on Jan. 28, 2004, U.S. patent application Ser. No. 10/782,275, filed on Feb. 19, 2004, U.S. patent application Ser. No. 10/781,994, filed on Feb. 19, 2004, U.S. patent application Ser. No. 10/806,544 filed Mar. 23, 2004 and U.S. patent application Ser. No. 10/823,065 filed Apr. 12, 2004, which are also commonly assigned and hereby incorporated by reference herein.
Continuation in Parts (4)
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Number |
Date |
Country |
Parent |
10781994 |
Feb 2004 |
US |
Child |
10851535 |
May 2004 |
US |
Parent |
10689858 |
Oct 2003 |
US |
Child |
10781994 |
Feb 2004 |
US |
Parent |
09946476 |
Sep 2001 |
US |
Child |
10781994 |
Feb 2004 |
US |
Parent |
10766052 |
Jan 2004 |
US |
Child |
10781994 |
Feb 2004 |
US |